Method of encasing brick



April 18, 1967 J. D. JENKINS ETAL METHOD OF ENCASING BRICK Original Filed June 5, 1963 4 Sheets-Sheet 1 INVEINTOR$ James D. Jenkins BY April 1967 J. D. JENKINS ETAL 3,314,142

METHOD OF ENCASING BRICK Ufiginal Filed June 1963 4 Sheets-Sheet 2 H i Fl! 1 R FOR VENTO JAMES l). JENKINS CHARLES I3. REYNOLDS April 18, 1967 D JEN'KINS ETAL 3,314,142

METHOD OF ENCASING BRICK Original Filed June a, 1963 4 Sheets-Sheet s AIR IN AIR OUT I TO: ATM,

BLEED 'AIR OIL

INVENTORS JAMES B. JENKINS REVERSE CHARLES B, REYNOLDS OIL FLOW April 1967 J. D. JENKINS ETAL 3,314,142

METHOD OF ENCASING BRICK Original Filed June 3, 1963 4 Sheets-Sheet 4 INVENIORS. JAMES D. JENKINS (:rmnms n. REYNOLDS F lg. 11

United States Patent 3,314,142 METHOD OF ENCASING BRICK James D. Jenkins, San Jose, and Charles B. Reynolds, Saratoga, Calif., assignors to Kaiser Aluminum & Chemical Corporation, Oakland, Calif., a corporation of Delaware Original application June 3, 1963, Ser. No. 285,093, now Patent No. 3,273,373, dated Sept. 20, 1966. Divided and this application May 25, 1964, Ser. No. 372,734

2 Claims. (Cl. 29-509) This application is a division of JamesD. Jenkins et al., S.N. 285,093, filed'June 3, 1963, now Patent No. 3,273,373.

This invention relates to a method for applying metal cases to bricks and more particularly it relates to a method for applying channel cases to refractory bricks.

It has long been the practice to install furnace linings, particularly in high temperature metallurgical furnaces, which linings comprise refractory bricks which are wholly or partially plated with metal. preferred bricks are nonacid refractory bricks, such as magnesia, chromite, spinel, forsterite or various admixtures of these compositions and they may be in either burned or chemically bonded state. It will be understood that other refractory materials than those men tioned have been useful and are being used for the linings of industrial furnaces. Problems have been encountered in the art of securing good surface contact between the brick and metal plate which surrounds it, and also in securing good attachment of the brick to the case. Many solutions have been proposed for this problem, such as co-molding at the time of formation of the brick, or welding of the various parts of the case together in the brick, or other means havebeen proposed and practiced; however, the problems of the art have not been satisfactorily and entirely solved by-the means heretofore proposed, either because of limitation of the method and means to an unburned brick or for the reason that the attachment of the brick to the casing has not been secure, or the means proposed have been expensive and not economical to practice in the art.

According to the present invention there is provided a method for aflixing one or more metal casesor a pair of metal cases to a refractory brick, in a rapid and economic manner; and in a manner. to insure secure attachment of the casing to the brick, and to assure that the casing will remain on the brick during subsequent ha11- dling, transportation and installation thereof.

In one embodiment of an apparatus suitable for carrying out the method of the invention, there is provided a means for forwarding a brick and an associated casing, which means is preferably a conveyor belt of the usual endless type, and there is also provided a support means which is a metal plate over which the belt travels, carrying the brick. As the brick enters the apparatus it suitably actuates a mechanism which initiates inward movement of punch means in such manner that when the brick reaches a predetermined point in its travel, the punch means are brought to bear upon the metal case directly over a preformed depression in a pair of side faces of the brick. In the preferred embodiment, the brick is stopped and is held at this. point while the punch means are forced inwardly, locally deforming and depressing the metal case into engagement with the surface of the preformed depression in the brick. The brick is so stopped by application of a stop means engaging or resting against its forward end face; and simultaneously in a preferred embodiment the brick with its casing is held down against the belt and the belt, in its turn, against the metal support plate mentioned above, by means of a swivel shoe clamp applied against the top face In general, the

3,314,142 Patented Apr. 18, 1967 of the brick and operated pneumatically, hydraulically, mechanically, or in any desired manner.

According to the present invention in a preferred embodiment there is provided means for supporting a brick bearing one or a pair of U-shaped cases and means for conveying it to a deformation or dimpling station. At this station, localized pressure is applied to the metal casing simultaneously at both sides of the brick to effect deformation of the metal casing in a localized area into conformity and frictional engagement with a shallow, discontinuous depression in the brick face beneath the metal plate.

After deformation of the metal is completed, the punch is retracted, this movement being initiated by suitable means when the pressure against the punch reaches a predetermined maximum value to avoid damage to the brick, removing the punch out of contact with the metal-encased brick. At the same time the stop means is withdrawn and the shoe clamp is retracted, enabling forward travel and removal of the dimpled, encased brick from the dimpling or pressing zone.

The invention will be described with reference to the accompanying drawings, wherein:

FIG. lis an elevation view of the apparatus of this invention at the area at which a brick will be introduced;

FIG. 2 is a front elevation view of the punch support and assembly; 7

FIG. 3 is a cross-sectional elevation side view of the punch assembly taken on line 3--3 of FIG. 2;

FIG. 4 is a plan view of the apparatus, with the brick hold-down and other parts not shown, for greater clarity; FIG. 5 is a side elevational view of the apparatus;

FIG. 6 is a plan view similar to FIG. 4 but showing the punches in contact with the encased brick;

FIG. 7 is a schematic diagram of one pneumatic and hydraulic control system useful in operating the apparatus according to this invention;

FIG. 8, preformed brick;

FIG. 9, preformed brick with associated casing;

FIG. 10, another embodiment of a preformed brick with associated casing; and

FIG. 11 is a perspective view of the apparatus.

In the drawings, 10 represents generally the dimpling apparatus of the present invention, including conveyor belt 11 which in the dimpling zone 17 rides on a support plate 12 and carries brick 13 bearing metal case 14, forward to and through the dimpling Zone. The brick is guided within the dimpling zone by guides 15 and 15 disposed above belt 11 and confining the encased brick, indicated generally by 16, as it passes to the dimpling station or zone and therethrough.

Brick 13 bearing associated casing 1.4 moves forward to the dimpling zone and is stopped at a predetermined point in its travel by stop means 18 which is suitably operated by an air cylinder 19 and in this embodiment comprises a flat plate of metal which is moved forwardly and downwardly to abut against the forward end or face 20 of the moving brick bringing it to a stop.

The preformed brick 13 is formed withone or a plurality of, preferably two, shallow, discontinuous depressions which are preferably contained wholly within a side face of such brick, as shown at 21, and a channelshaped casing 14, which is laid on the brick or loosely associated therewith prior to deforming, extends over part or all of each such depression as shown in FIGS. 8, 9 and 10. These depressions are of diminutive area with respect to the brick face in which they are located; and,

although in the drawings they are shown as being placed line of the side face in most embodiments, however. Also, it Will be understood that two-such depressions are prefera bly located on opposing side faces of such brick. The depressions in the brick may be hemispherical, cylindrical, square, diamond-shaped or any desired configuration, and are usually from one-half to one inch in diameter; and in the usual embodiment the depressions are substantially hemispherical. The depressions can be formed in the brick at the time of pressing, casting or otherwise shaping the same, or can be ground or drilled after formation of the brick, but in any event are formed prior to application of the metal casing. It will also be understood that the brick can be in either burned or chemically bonded state.

Disposed at one side of the conveyor belt is a suitable light source, e.g., a 25-watt bulb, 22 and at the other side a photoelectric cell 23 for suitable activation of motion of the various elements as will be further described below. Disposed on each side of the dimpling zone is one or more, preferably there are two, punch assemblies suitably mounted for forward and back horizontal motion. In the drawings each dimpler punch 24 having in this embodiment rounded contact end surface 25 is afiixed to plate 26. Plate 26 is mounted on support means 27 by means of a threaded rod or bolt 28 provided at its rear or opposite end from plate 26 with a nut 29 with suitable washer 38, whereby the plates can be loosened and rotated against support 27 through a 360 angle, thereby providing a vertical adjustment of the punch. Plates 26 are also movable or slidable horizontally in slot 30 of support 27. Support 27 is supported by and movable horizontally with respect to rails or support means 31 and 32, to move the punches against and away from the metal encased brick. Suitably support means 27 is moved forwardly and retracted by means of hydraulic cylinder 33 of conventional construction. Two such cylinders are provided for each support 27, preferably. Although in the embodiment described above the punch means are provided with rounded contact surfaces, in an alternative embodiment the punch means is provided with a piercing surface which deforms or depresses the metal into the preformed depression and simultaneously pierces the same to provide the pierced opening in the metal case with prongs which enable greater frictional engagement with the surface of the depression.

Disposed above the dimpling zone in such manner as to be brought to bear upon the brick, preferably at the midpoint of its length, is pressure shoe 34 which is mounted by a swivel joint 35 on rod 36 operated, in this embodiment, by pneumatic or air cylinder 37 of conventional construction.

In the method of operation of the present invention, a brick 16 is forwarded into dimpling zone 17 by means of conveyor 11. In its forward travel it interrupts a light beam from light source 22 to photoelectric cell 23, in the embodiment shown in the drawings this occurring as the brick passes between the first and second dimpling punches disposed in series. This moves relay switch 40 to close the circuit which energizes solenoid twoaway valve 41 and enables flow of air under 90 lbs. per square inch pressure into cylinder 37 to initiate downward movement of pressure shoe 34 toward brick 16. When the pressure in cylinder 37 reaches a predetermined value, shoe 34 being in contact with brick 16, pressure switch 42 in series therewith closes and energizes solenoid valve 43 which enables flow of air into a booster cylinder 44. Booster cylinder 44 is of well known construction in which lower 'pressure air presses on a large piston which transmits such pressure to a smaller piston in contact therewith, i.e., transmitting the total force resulting from the pressure of air on the large piston and resulting in pressure increase (per square inch) as transmitted by the small piston. The increased pressure is transmitted by the smaller piston to oil which is fed to the hydraulic cylinder .33 which is attached to and actuates, or controls, the

motion of support 27, causing it to move on rails 31 and 32. The transmission .ofthis oil under increasedpressure to hydraulic cylinders 33 causes support 27 and with it punch means 24 to move inwardly toward and into contact with the metal casing on the brick. Punch means 24 each register withpreformed depression 21 in the side face of the brick; and contact end 25 of punch 24 locally deforms and depresses metal casing 14 into engagement with the surface of preformed depression 14. It will be understood that the contact end 25 of each punch 24 is suitablyselected to conform generally with the contour of depression 14, i.e., when the depression is rounded it is preferred that the contact at the end of the punch be rounded and smooth in one embodiment, whereas if the depression has been ground out to a cylindrical form the contact end punch 24 is preferably also cylindrical in form. Alternatively, as mentioned hereinabove,

.pressure effectively increases as the metal comes into contact with the surface of the brick depression; and pressure switch 45 closes when a preset pressure is reached in this operation, 'for example, a pressure of 3150 p.s.i., so selected as to avoid any damage to the brick structure. Pressure switch 45 upon closing energizes time delay switch 46, reversing the action of solenoid valves 41, 39 and 43, effecting retraction of the clamp or hold-down shoe 34, stop 18 and dimpling punches 24, time delay switch 46 being set to hold the circuit for solenoid valves 39, 41 and 43 closed until the dimpled encased brick has been conveyed by belt 11 beyond stop 18. When time delay switch 46 opens or reverses after such travel of the brick and suitable time set, solenoid valve 39 is again energized to enable air flow to cylinder 19 to move stop 18 downwardly in preparation for stopping the next brick in line.

.As the brick and its associated casing are moved into and along the dimpling zone, in the embodiment described herein, the mass interrupts a light beam which actuates a photoelectric cell, which in turn actuates a holddown means to hold the brick and conveyor belt stationary against a metal support plate. This has the advantage that the life of the belt is increased because it does not move against the brick of which the portion resting on the belt can bear a metal case,or, alternatively, can be uncased, with a metal casing laid over the top portion of the brick only. At the same time, the punch means at both sides are simultaneously moved inwardly to locally deform and depress the metal casing into conformity and frictional engagement with the brick to a predetermined limit of travel, controlled by maximum contact pressure, e.g., suitably for nonacid brick of 3500 to 4000 p.s.i., to prevent damage to the brick structure. When such maximum pressure is attained, the punch means, stop means and hold-down means are retracted, and the brick bearing the affixed, dimpled casing is conveyed out of the dimpling zone and is ready for storing, shipping or further handling.

It is an advantage of this invention that there is provided an apparatus and method for rapidly affixing a metal casing to a brick; and a further advantage is that this is done without damage to the brick. Another advantage is that the apparatus is adaptable to various sizes and shapes of bricks, the punch means each being adjustable both vertically and horizontally, with respect to the brick on the conveyor belt. Bricks encased according to the present invention are useful in open hearth furnace walls and roofs, hot zones of rotary cement kilns, and in many other high temperature furnace linings. A special advantage is that a hydraulic means for actuating the punch means ensures controlled application of power or thrust and avoids shock impact.

It will be understood that metal cases which are affixed in the manner of the invention can be of ferrous or other metal. Although the invention has been illustrated as applied to abrick of equidimensional ends and of sides which are parallel to the long axis, i.e., a straight brick, it will be understood that arch brick, wedge brick and bricks of varying dimensions can be encased according to the present invention, especially by means of the adjustable punch means. The preformed depressions are shown in certain of the figures as lying below the outer edge of a channel case arm but alternatively such depressions can be wholly overlain or covered by the case, or otherwise located so as to receive deformed and depressed metal.

The above description and specific embodiment have been given as illustrative only and it is to be understood that variations and modifications can be made therein without departing from the spirit and scope of the invention, as defined in the appended claims, wherein what is claimed is:

1. In a method of encasing a preformed nonacid refractory brick, the steps of which comprise placing a channel-shaped metal casing on such brick so as to cover at least a portion of each of a plurality of adjacent side faces thereof, said brick having a preformed shallow, discontinuous depression in each of a pair of opposing side faces thereof and said metal casing at least partly overlying said depressions, conveying said brick and associated casing to a dimpling zone, and there simultaneously maintaining said brick stationary and by opposing punches applying up to a predetermined maximum local pressure without impact shock to said metal casing in registry with each said depression to a limit of travel of the punches to locally deform and depress said easing into conformity and frictional engagement with said depression.

2. In a method of encasing a preformed basic refractory brick having end faces and side faces and having at least one shallow, discontinuous depression in each of a pair of opposing side faces, the steps which comprise placing a channel-shaped metal case on such brick so as to cover at least a portion of three adjacent sides thereof and to overlie at least a portion of each said depression, conveying said brick and associated casing to a dimpling zone, and there simultaneously maintaining said brick stationary and by opposing punches locally applying up to a maximum of 4000 psi. pressure without impact shock to said metal casing localized in registry with each said depression to a limit of travel of the punches to locally deform and depress said casing into conformity and frictional engagement with said depression.

References Cited by the Examiner UNITED STATES PATENTS 3,083,453 4/1963 Reynolds et al.

CHARLTE T. MOON, Primary E Jtamir er, 

1. IN A METHOD OF ENCASING A PREFORMED NONACID REFRACTORY BRICK, THE STEPS OF WHICH COMPRISE PLACING A CHANNEL-SHAPED METAL CASING ON SUCH BRICK SO AS TO COVER AT LEAST A PORTION OF EACH OF A PLURALITY OF ADJACENT SIDE FACES THEREOF, SAID BRICK HAVING A PREFORMED SHALLOW, DISCONTINUOUS DEPRESSION IN EACH OF A PAIR OF OPPOSING SIDE FACES THEREOF AND SAID METAL CASING AT LEAST PARTLY OVERLYING SAID DEPRESSIONS, CONVEYING SAID BRICK AND ASSOCIATED CASING TO A DIMPLING ZONE, AND THERE SIMULTANEOUSLY MAINTAINING SAID BRICK STATIONARY AND BY OPPOSING PUNCHES APPLYING UP TO A PREDETERMINED MAXIMUM LOCAL PRESSURE WITHOUT IMPACT SHOCK TO SAID METAL CASING IN REGISTRY WITH EACH SAID DEPRESSION TO A LIMIT OF TRAVEL OF THE PUNCHES TO LOCALLY DEFORM AND DEPRESS SAID CASING INTO CONFORMITY AND FRICTIONAL ENGAGEMENT WITH SAID DEPRESSION. 